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Home >> Toyota Truck >> 2011 >> Highlander 4WD V6-3.5L (2GR-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Engine Assembly >> Installation

Installation





2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR

(a) Install the transverse engine mounting insulator with the 2 nuts.





Torque : 52 Nm (525 kgf-cm, 38 ft-lbf)

(b) Install the 2 hole plugs.





2. INSTALL ENGINE HANGERS

(a) Install the 2 engine hangers with the 4 bolts as shown in the illustration.





Part No.:

No. 1 Engine hanger 12281-31120

No. 2 Engine hanger 12282-31100

Bolts 91671-10825

Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)

(b) Attach the engine sling device and hang the engine with the chain block.

3. REMOVE ENGINE STAND

4. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Installation

5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)

6. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 4WD) Installation

7. INSTALL TRANSFER STIFFENER PLATE RH (for 4WD) Installation

8. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

9. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD) Installation

10. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD) Installation

11. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET

(a) Install the transverse engine mount bracket with the 3 bolts.





Torque : 64 Nm (650 kgf-cm, 47 ft-lbf)

12. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY

(a) Temporarily install the front engine mounting insulator assembly with the nut.





13. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR

(a) Temporarily install the transverse engine mounting insulator with the nut.





14. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR

(a) Temporarily install the transverse mounting insulator with the nut.





15. INSTALL FRONT FRAME ASSEMBLY

(a) Temporarily install the engine assembly with transaxle with the 9 nuts and 2 bolts.





(b) Tighten the 4 nuts.





A - Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)

B - Torque : 52 Nm (525 kgf-cm, 38 ft-lbf)

(c) Tighten the 4 nuts.





A - Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

B - Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)

(d) Tighten the 4 nuts.





A - Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

B - Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)

(e) Tighten the 2 bolts.





Torque : 78 Nm (795 kgf-cm, 58 ft-lbf)

(f) Connect the duty vacuum switching valve connector and clamp.





(g) Install the 5 hole plugs.





16. INSTALL POWER STEERING LINK ASSEMBLY (for 4WD) Installation

17. INSTALL FRONT STABILIZER BAR

HINT
Installation.

18. REMOVE ENGINE HANGERS

(a) Remove the 4 bolts and 2 engine hangers.





19. INSTALL MANIFOLD STAY

(a) Install the bolt, nut and manifold stay.





Torque : 34 Nm (347 kgf-cm, 25 ft-lbf)

20. INSTALL STARTER ASSEMBLY Installation

21. INSTALL ENGINE WIRE

(a) Install the 3 bolts.





Torque : 8.3 Nm (85 kgf-cm, 74 in-lbf)

(b) Connect the 2 clamps, 3 ignition coil assembly connectors, 2 camshaft timing oil control valve assembly connectors, 2 VVT sensor connectors, 3 injector assembly connectors and radio setting condenser connector.

(c) Install the bolt and 2 nuts.





Torque : 8.3 Nm (85 kgf-cm, 74 in-lbf)

(d) Connect the 2 clamps, 3 ignition coil assembly connectors, 2 camshaft timing oil control valve assembly connectors, 2 VVT sensor connectors and 3 injector connectors.

(e) Connect the air fuel ratio sensor connector.

(f) Connect the 2 clamps, engine coolant temperature sensor connector and knock control sensor wire connector.





(g) Install the ground cable bolt.

(h) Connect the purge VSV connector, air fuel ratio sensor connector and 2 clamps.





(i) Install the nut.





Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

(j) Connect the generator assembly connector and clamp.

(k) Connect the crankshaft position sensor connector and clamp.





(l) Connect the oil pressure switch assembly connector.





(m) Connect the oil pressure switch assembly cover.





22. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

NOTICE:
Do not apply oil to the bolts as listed below:





(a) Install a new gasket to the intake air surge tank.

(b) Using a 5 mm hexagon socket wrench, install the 4 bolts and 2 nuts.





Bolt - Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

Nut - Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)

(c) Install the throttle body bracket, No. 1 surge tank stay and 4 bolts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(d) Connect the connector.





(e) Connect the No. 1 ventilation hose.

(f) Install the clamp and connect the throttle with motor body assembly connector.





(g) Connect the vapor feed hose.

(h) Connect the 2 water by-pass hoses to the throttle with motor body assembly.

23. INSTALL VENTILATION HOSE

(a) Using pliers, grip the claws of the 2 clips and slide the 2 clips to the intake air surge tank assembly and ventilation valve.





24. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH Installation

25. INSTALL COMPRESSOR AND MAGNETIC CLUTCH

(a) Install the compressor and magnetic clutch with the 4 bolts.





Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.

(b) Engage each clamp.





(c) Engage the clamp.

(d) Connect the connector.

26. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine assembly with transaxle on the engine lifter.

(b) Install the engine assembly to the vehicle.

(c) Install the frame side rail plates RH and LH with the 6 bolts and 2 nuts.





A - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)

B - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

(d) Install the front suspension member rear braces RH and LH with the 6 bolts and 2 nuts.





A - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)

B - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

27. RECONNECT SUCTION HOSE SUB-ASSEMBLY Installation

28. RECONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation

29. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY Installation

30. INSTALL FRONT AXLE ASSEMBLY LH Installation

31. INSTALL FRONT AXLE ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

32. INSTALL NO. 1 FRONT SUSPENSION LOWER ARM LH Installation

33. INSTALL NO. 1 FRONT SUSPENSION LOWER ARM RH

HINT
Use the same procedure described for the LH side.

34. INSTALL TIE ROD ASSEMBLY LH Installation

35. INSTALL TIE ROD ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

36. INSTALL FRONT SPEED SENSOR LH Installation

37. INSTALL FRONT SPEED SENSOR RH

HINT
Use the same procedure described for the LH side.

38. INSTALL FRONT AXLE HUB NUT LH Installation

39. INSTALL FRONT AXLE HUB NUT RH

HINT
Use the same procedure described for the LH side.

40. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

41. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

42. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

43. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY Installation

44. INSTALL CENTER EXHAUST PIPE ASSEMBLY Installation

45. INSTALL TAIL EXHAUST PIPE ASSEMBLY Installation

46. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY Installation

47. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY Installation

48. CONNECT ENGINE WIRE

(a) Connect the 3 ECM connectors, 2 junction block connectors and clamp.





(b) Install the engine wire with the 2 nuts.





Torque : 8.3 Nm (84 kgf-cm, 73 in-lbf)

(c) Install the clip and 2 ground cables with the 2 bolts.





Torque : 8.3 Nm (84 kgf-cm, 73 in-lbf)

(d) Connect the heated oxygen sensor clamp and connector.





(e) Connect the engine wire clamp.





(f) Install the ground cable with the bolt.





Torque : 8.3 Nm (84 kgf-cm, 73 in-lbf)

(g) Connect the engine wire to the engine room relay block. Then, install it with the nut.





Torque : 8.3 Nm (84 kgf-cm, 73 in-lbf)

(h) Connect the engine wire connector.

(i) Install the No. 1 relay block cover.

49. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Connect the control cable to the control cable clamp.





(b) Install the transmission control cable assembly to the control shaft lever with the nut.





Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

(c) Connect the transmission control cable assembly to the bracket with a new clip.





50. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Push in the fuel tube connector to the fuel pipe until the fuel tube makes a "click" sound.





NOTICE:
* Check for damage or dirt and foreign objects on the connected part of the pipe.
* Check if the pipe and the connector are securely connected by trying to pull them apart.

(b) Install the No. 1 fuel pipe clamp.





51. CONNECT OIL COOLER OUTLET HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to connect the oil cooler outlet hose.





52. CONNECT OIL COOLER INLET HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to connect the No. 2 oil cooler hose.





53. CONNECT HEATER WATER HOSE INLET B

(a) Using pliers, grip the claws of the clip and slide the clip to connect the heater water inlet hose B to water outlet.





54. CONNECT HEATER WATER HOSE OUTLET B

(a) Using pliers, grip the claws of the clip and slide the clip to connect the heater water outlet hose B to water inlet.





55. INSTALL NO. 1 RADIATOR HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to connect the No. 1 radiator hose to the water outlet.





(b) Install the clamp with the air fuel ratio sensor connector.

56. INSTALL NO. 2 RADIATOR HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to connect the No. 2 radiator outlet hose to the water inlet.





57. CONNECT UNION TO CHECK VALVE HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to connect the union to check valve hose to the intake air surge tank assembly.





58. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Install the clamp and connect the No. 1 fuel vapor feed hose.





59. INSTALL ENGINE MOVING CONTROL ROD

(a) Temporarily install the engine moving control rod with the 3 bolts.





(b) First install bolts A, and then bolt B.

Torque : 38 Nm (388 kgf-cm, 28 ft-lbf)

60. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Temporarily install the No. 2 engine mounting stay RH with the bolt.





Torque : 38 Nm (388 kgf-cm, 28 ft-lbf)

(b) Tighten the 2 nuts.

Torque : 23 Nm (235 kgf-cm, 17 ft-lbf)

61. INSTALL RESERVOIR BRACKET

(a) Install the reservoir bracket with the 2 bolts.





Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

62. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

(a) Install the brake master cylinder reservoir assembly with the bolt.





Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

(b) Connect the level warning switch connector.

63. INSTALL AIR CLEANER BRACKET

(a) Install the 2 bolts and air cleaner bracket.





Torque : 12 Nm (123 kgf-cm, 9 ft-lbf)

64. INSTALL BATTERY

(a) Install the battery tray and battery.





(b) Install the battery clamp with the bolt and nut.

Bolt - Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

Nut A - Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

Nut B - Torque : 13 Nm (131 kgf-cm, 9 ft-lbf)

Nut C - Torque : 6.4 Nm (64 kgf-cm, 57 in-lbf)

(c) Install the positive battery terminal and nut.

(d) Connect the negative battery terminal, and tighten the nut.

65. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation

66. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

(a) Install the air cleaner filter element sub-assembly.

67. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

68. INSTALL NO. 1 AIR CLEANER INLET Installation

69. INSTALL NO. 2 AIR CLEANER INLET Installation

70. CONNECT VACUUM HOSES





71. INSTALL V-RIBBED BELT Installation

72. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

(a) Install the front outer cowl top panel sub-assembly with the 8 bolts and 6 nuts.





Bolt - Torque : 8.8 Nm (90 kgf-cm, 78 in-lbf)

Nut A - Torque : 8.8 Nm (90 kgf-cm, 78 in-lbf)

Nut B - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)

(b) Install the 4 clips.





73. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

74. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

75. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

76. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

77. INSTALL FRONT WHEELS

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

78. ADD ENGINE OIL Replacement

79. ADD ENGINE COOLANT Service and Repair

80. ADD AUTOMATIC TRANSAXLE FLUID

81. CHECK AUTOMATIC TRANSAXLE FLUID

82. INSPECT FOR FUEL LEAK Fuel System

83. INSPECT FOR ENGINE OIL LEAK Replacement

84. INSPECT FOR COOLANT LEAK Testing and Inspection

85. INSPECT FOR EXHAUST GAS LEAK Installation

86. CHECK SHIFT LEVER POSITION

87. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

HINT
Front Wheel Alignment.

88. CHECK IGNITION TIMING Engine

89. CHECK ENGINE IDLE SPEED Engine

90. CHECK CO/HC Engine

91. CHECK FUNCTION OF THROTTLE BODY ASSEMBLY On-Vehicle Inspection

92. INSTALL FRONT FENDER APRON SEAL RH

(a) Install the front fender apron seal RH with the 2 bolts and clip.





93. INSTALL FRONT FENDER APRON SEAL LH

(a) Install the front fender apron seal LH with the 2 bolts and clip.





94. INSTALL FRONT FENDER LINER LH Installation

95. INSTALL FRONT FENDER LINER RH Installation

96. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY LH Installation

97. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY RH Installation

98. INSTALL FLOOR UNDER COVER LH

99. INSTALL NO. 2 ENGINE UNDER COVER

(a) Install the No. 2 engine under cover with the 2 bolts.





100. INSTALL NO. 1 ENGINE UNDER COVER

(a) Install the No. 1 engine under cover with the 6 bolts and 2 clips.





101. INSTALL ENGINE UNDER COVER ASSEMBLY

(a) Install the engine under cover assembly with the 4 bolts and 5 clips.





(b) Install the engine under cover assembly RR with the 2 bolts.





102. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Fit the 3 retainers and install the V-bank cover.





103. CHECK ABS SPEED SENSOR SIGNAL

Test Mode Procedure

104. RESET MEMORY

HINT
Repair Instruction - Initialization.

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